WO2005096888A1

WO2005096888A1 - Method and apparatus for forming an article of manufacture and an article of manufacture made by a new and novel process

Info

Publication number: WO2005096888A1
Application number: PCT/US2005/010231
Authority: WO
Inventors: Joseph Wycech
Original assignee: Joseph Wycech
Priority date: 2004-04-02
Filing date: 2005-03-25
Publication date: 2005-10-20
Also published as: US20050221074A1; US7300616B2; CA2561623A1; TW200534986A

Abstract

A method (10) to selectively produce an article of manufacture (20) having desirable properties and which may replace many “ceramic based” articles. Particularly, the article of manufacture (20) is made by selectively combining an epoxy structural foam material (110) with a catalyst (111) and a drying agent (200). The mixed material is then selectively dispensed within a mold (16) and allowed to harden in order to form the article of manufacture (20). Alternated formulations may be utilized.

Description

METHOD AND APPARATUS FOR FORMING AN ARTICLE OF MANUFACTURE AND A ARTICLE OF MANUFACTURE MADE BY A NEW AND NOVEL PROCESS

Field of the Invention The present invention generally relates to a method and an apparatus for forming an article of manufacture and an article, of manufacture made by and from a new and novel process and, more particularly by way example and without limitation, to a ^' method and apparatus which allows an article of manufacture to be made in a cost effective manner, having properties, which are highly desirable, and to be made in a variety of shapes and sizes, thereby

^• increasing the overall ^' utility and -usefulness of the process and, by ^• way of- _. further , example and without limitation, to allow the formed articles of manufacture, to replace current "ceramic type" articles.

Background of the Invention "Ceramic type" article of - manufactures are used in a wide variety of applications and form many common articles used by the general • public. Some non-limiting examples- of these articles include toilet bowels and kitchen sinks. Particularly, such articles are made by the use of traditional types of clay material which is generally formed into ^■ a desired shape and then placed within and heated by kilns. The heat causes the clay to harden and the hardened articles are then removed from ^■ the kiln and "finished" by hand. While the foregoing ceramic type articles, do provide a desired 'function, they suffer from many drawbacks. For example, the foregoing article creation process is labor intensive, thereby greatly increa-sing the cost of producing ^• these articles. Since the formed articles are relatively heavy, the labor costs cannot be economica-lly reduced by creating the articles in a location, relatively far away from their intended use, where labor costs --are inexpensive (i.e., while labor- costs may be reduced, the shipping costs would greatly increase) . Further, the foregoing process a-Lso _. does not economically allow articles to be produced of greatly varying size and shapes and the required "hand finishing" oftentimes causes inadvertent damage and/or destruction to the formed article, thereby further increasing overall cost . There is' therefore a need for a new and novel me hod and apparatus to produce articles of manufacture which overcomes .at- least ^' some of the previously deline ated drawbacks associated with the production of these "cer amic type" articles and which may be used to produce article s to replace other "non-ceramic" types of articles . Summary of the Invention It is a first non-limiting object of the pre sent invention to. provide a method and apparatus which selectively allows articles of manufacture to be made -±n .a manner which overcomes some or all of the previously delineated drawbacks associated with the creation of "ceramic type" articles of manufacture. It is a second^' non-limiting object of the present invention to provide a method and an apparatus which selectively allows articles of manufacture to be made -in a wide variety of sizes and shapes and having desirable

' properties. It is a third non-limiting object of the pre sent 'invention to provide a method and an apparatus for producing articles of manufacture in -a cost effective manner. It is a fourth non-limiting object of the pre sent invention to provide an article of manufacture ha -ving properties which are superior to "ceramic type" articles of manufacture and which may be produced in a cost effective manner .• According to first non-limiting aspect of the^' present invention, a method is provided for creating an article of manufacture. Particularly, the method includes the steps of providing a structural epoxy foam material; providing a catalyst; mixing the structural epoxy foam material with the catalyst, thereby creating a certain mixture; creating .a . mold; placing the certain mixture within the created mold; and allowing the certain mixture to harden within the created mold, thereby forming the article of manufacture. According to a second non-limiting aspect of the present invention, -a method is provided for creating an article of manufacture. Particularly, the method includes the steps of providing a syntactic cement material; providing a catalyst; mixing the syntactic cement material with the provided catalyst, thereby creating a certain mixture; creating a mold; placing the certain mixture within the created mold; and allowing the certain mixture to harden within the created mold, thereby creating the article of manufacture. According to a third non-limiting aspect of the present invention, an apparatus for selectively forming an article of manufacture is provided. Particularly, the apparatus includes a mold; a reservoir of a catalyst; a reservoir of a structural foam material; a pump which is physically and communicatively coupled to the reservoir of structural foam material; a mixing head assembly which is physically and ^"communicatively coupled to the pump and which includes an auxiliary input port and an output 'port; a source' of gas which is physically and communicatively coupled to the auxiliary input port; a mixing assembly which is physically and communicatively coupled to the output port of the mixing head ^' assembly; and a controller which is controll_.ably coupled to the pump, to the source of gas, and to the mixing assembly and wherein the controller is adapted to selectively cause at least a portion of the reservoir of structural foam material to be communicated to the input port of the mixing head assembly while causing at least, a portion of the source of gas to be communicated to the auxiliary input port of the mixing head assembly , thereby causing at least the. portion of the source of gas to mix with the at least the porti.on of the reservoir of structural foam within the mixing head assembly to form a certain material, the controller further selectively causing the formed certain material to be communicated to the^' mixing assembly' and causing the , formed certain material to mix with at least a portion of the catalyst- material' within the mixing assembly to form a certain second material and further selectively causing at least- a portion ^'of the formed^' certain second material to be ^' selectively dispensed from the mixing assembly to the mold, thereby allowing the certain second material to form the article of manufacture within the mold. According to' -a fourth nbn-limiting aspect of the present invention, an apparatus for selectively forming an article of manufacture is provided. Particularly, the apparatus includes- a mold; a reservoir of a catalyst; a reservoir of^' a syntactic cement; a pump which is physically and communicatively coupled to the reservoir of syntactic cement; a mixing head assembly which is physically and communicatively coupled to the pump and which includes an auxiliary input port and an output port; a source of gas which is physically and communicatively coupled to the

•auxiliary input port; a mixing assembly which is physically- and_. communicatively coupled to the output port of the mixing head assembly; -and- a controller, which is controllably coupled to the pump, to the source of gas, and to the mixing assembly and wherein the controller is adapted to selectively cause at least a portion of the reservoir of syntactic cement to be communicated to the input port of the mixing -head assembly while causing at least a portion of the source of gas to be communicated to the auxiliary input port of the mixing head assembly , thereby causing at least the portion of the source of gas to mix with the at least the portion of the reservoir of syntactic cement within the mixing head assembly to form a - certain material, the controller further selectively causing ^' the formed certain material to be communicated to the mixing _. assembly . and causing the formed certain material to mix with at least a portion of the catalyst material within the mixing assembly to form a certain second material and further selectively causing at least a portion of the formed certain second material to be selectively dispensed from the mixing assembly to the mold, thereby allowing the certain second material to form the article of manufacture within the mold. According to a fifth . non-limiting aspect of the present invention, an article of manufacture is provided. • Particularly,^' the provided article of manufacture is made- - by the process of mixing a structural foam material with a catalyst material to form a selectively mixed material; placing the selectively mixed material into a mold; and allowing the selectively mixed material to harden within the mold, thereby forming the article of manufacture.- According to a sixth non-limiting aspect of the present invention, an article of manufacture is provided. Particularly, the provided article of manufacture is made by the process of mixing a syntactic cement material with a catalyst material to form a selectively mixed material; placing the selectively mixed material into a mold; and allowing the selectively mixed material to harden within the mold, thereby forming the article of manufacture. These and other aspects, objects., and advantages of the present inventions will become apparent to ^• one of ordinary skill in the art by reading the following detailed description of the preferred embodiment of the invention and by reference to the following drawings.

Brief Description of the Drawings Figure 1 is a block diagram of an article creation apparatus ^" made in accordance with the teachings of the preferred embodiments of the invention; and Figure 2 is -a flow chart illustrating the sequence of steps associated with and comprising a first article formation methodology of the preferred embodiments of the invention. Detailed Description of the Preferred Embodiment of the Invention

Referring now to Figure 1, there is shown a article creation apparatus 10 which is made in accordance with the teachings of the preferred embodiments of the invention. Particularly, the apparatus 10 includes a material reservoir 12 which, in one non-limiting embodiment of the invention, contains structural epoxy foam material such as but not limited to a material from the family of structural foam materials commonly known as Teorcore ■ and available from the Henkel Corporation. The apparatus 10 further includes a controller assembly 14 which is operable under stored program control and which, in one non-limiting embodiment of the invention, comprises a Dell type computer operating in a Windows environment. The apparatus 10 further includes a mold 16 which is adapted to have a cavity 18 which conforms to the size and shape of a desired part or- article of manufacture 20. The apparatus 10 further includes a catalyst source 22 which is operably coupled to a pump 24. The pump 24 is controllably coupled to the controller assembly 14 by the use of bus- -30. The apparatus 10 further includes a source of a drying agent 40 which is also operably connected to a pump 44. The pump 44 is also controllably coupled to the controller 14 by the use of the bus 30. As is further shown in Figure 1, the apparatus 10 includes a dispensing head assembly 50 having a first input port 52 which is communicatively coupled to the pump 24 and a second input port 54 which -is communicatively coupled to the pump.44.. The apparatus 10 also includes a pump 60 which is communicatively and operably coupled to . the material reservoir 12 and which is further communicatively coupled to the input port 70 of the dispensing head assembly 50. The controller - assembly 14 is controllably coupled ^' to the pump 60 by trie use of bus 30. In an alternate embodiment of the invention, the apparatus 10 includes a vibration assembly 80 which is physically coupled to- the dispensing head assembly 50 and which is controllably coupled to the controller -assembly 14 by the use of bus 30. In one non- limiting embodiment of the invention, the dispensing head assembly 50 may comprise a model "Twinmixer III" which is provided by the Liquid Control Corporation of North Canton, Ohio a d the pump may comprise a model "PosiFlow" programmable continuous flow metering pump or "zero shear pump" which is also provided by the Liquid Control Corporation. The apparatus 10 also includes a source of electrical energy 15 which is coupled to the controller assembly 14 by the use of bus 17. Referring now to Figure 2, there is shown a flow chart ^' 100 which illustrates one methodology 100 which may be used according to the invention. Particularly, the methodology 100 includes a first step 102 in which all of the various " ^' foregoing elements of the apparatus 10 are "reset" or made ready to begin the overall process 100. The first step 102 is followed by step 104 in which a mold, such as mold 16, . is created or provided and which has a desired cavity 18 having a size and a shape which conforms to the size and the shape of a desired article of manufacture, such as article of manufacture 20. Step 104 is followed by step 106 in which the structural foam material 110 is provided within the reservoir 12.- Step ^"106 follows step 104 and, in this step 106, a catalyst material 111 is provided within the source reservoir 22. In one non-limiting embodiment of the invention, this catalyst material 111 comprises an Amine type catalyst, although other catalyst materials may be utilized. Step 108 is followed by step 120 in which the catalyst material 111 is mixed with the epoxy structural foam material 110 within the head assembly 50. Particularly, ^' by way of example and without limitation, such mixing occurs after the controller ^' assembly 14 selectively activates the pumps 60 and 24 (e.g., by sourcing electrical energy to these pumps 24, 60 from the - source 15 and by the use of bus 30) to respectively cause the materials 110 and 111 to be communicated into the head assembl 50. In an alternate embodiment of the invention, the controller assembly 14 also selectively activates the vibration assembly 80, by sourcing electrical energy to the vibration assembly 80 from the source 15 and by the use of - bus 30.- This vibration occurs in step 122 which follows step 120. Step 124 follows either step 122 or step 120 and, ^• in this step 124, the, controller assembly 14 .sources - electrical energy, from the source 15 to the pump 44, to cause the drying agent 200 to be communicated into the head assembly 50 ^' as the epoxy structural foam 110 and the catalyst 111 are being mixed within the. head assembly 50. In yet another alternate embodiment, of the invention, the drying agent -may first be heated before it is communicated into the head assembly 50. In one alternate embodiment of the invention, the drying agent 200 comprises air. In yet another alternate embodiment of the invention, the mixed foam ilO, catalyst 111, and the drying agent 200 are each vibrated within the head assembly 50 as they are selectively mixed within the head assembly 50. Step 222 follows step 124 and, in this- step 222, the mixed material within the head assembly 50 is dispensed into the mold 20 (i.e., into the formed cavity 18 within the mold 20) . Step 224 follows step 222 and, in this step 224, the dispensed material is allowed to harden. Step 226 follows step 224 and, in this step 224, the hardened material is removed from the mold 20, thereby forming an article of manufacture 20. Step 228 follows step 226 and represents the conclusion of the methodology 100. .- In an alternate embodiment of the invention, the material 110 comprises syntactic cement and the catalyst material 111 comprises water. In- yet another alternate embodiment of the invention, the drying agent 200 comprises liquid carbon dioxide. It should be appreciated that the article of

- manufacture 20 is very resistant to acid damage, is lightweight, and may be configured in a wide variety of sizes and shapes and has the strength and structural integrity of ceramic based articles of manufacture. Hence, the article of manufacture 20 may comprise a toilet bowl, sink,^' countertop, or virtually any other desired article. It should be further appreciated that placing the drying agent within the head assembly 50, as opposed to communicating the drying agent to the reservoir 12, allows the .dispensing material to have a relatively constant compressibility and better control. That is, the foam compresses as it is pumpably communicated to the head and placing a drying agent within the foam, before it is pumped, will cause the foam to have uneven compressibility and cause the pump 60 to expend greater and variable amounts of energy. In yet another^' non-limiting embodiment of the invention, microsphere material may be selectively added to the syntactic cement. It is to be understood that the invention is not limited to the exact construction and method which has been illustrated, but that various changes and- modifications may be made without departing from the spirit and the scope of the inventions as they are delineated in the following claims.

Claims

What Is Claimed Is : (1) A method of creating an article of manufacture, said method comprising the steps of providing a structural epoxy foam material; providing a catalyst; mixing the structural epoxy foam material with the catalyst, thereby creating a certain mixture; creating a mold; placing the certain mixture within said created mold; and allowing the certain mixture to harden within the created . mold, thereby forming the article of manufacture.

(2) The method of Claim 1 wherein said structural epoxy foam material comprises Terocore.

(3) The method of Claim 2 wherein said catalyst comprises an amine catalyst.

(4) The method of Claim 3 further comprising the steps of providing a source of gas; and causing at least a portion of said provided gas to be mixed with said structural epoxy foam material and said catalyst.

(5) The method of Claim- 4 further comprising the steps of vibrating said structural epoxy foam material and said catalyst as said structural foam material and said catalyst are being mixed.

(6) ^'The method of Claim 5 further comprising the step of heating said gas.

(7) The method of Claim 6 wherein said gas comprises air.

(8) The method of Claim 7 wherein said article of manufacture comprises a toilet bowl.

(9) The method of Claim -7 wherein said article of manufacture comprises a kitchen countertop.

(10) The method of Claim 7 . wherein said article of manufacture comprises a sink.

(11) A method of creating an article of manufacture, said method comprising the steps of providing a syntactic cement material; providing a catalyst; mixing said syntactic cement material with said provided catalyst, thereby creating a certain mixture; creating a mold; placing said certain mixture within said created -mold; and allowing said certain mixture to harden within said created mold, thereby creating said article of manufacture.

(12) The method of Claim 11 wherein said catalyst material comprises water.

(13) The method of Claim 12 further comprising the steps of providing a certain amount of microsphere material; and mixing said certain amount of said microsphere .material with said syntactic cement material.

(14) The method of Claim 13 wherein said article of manufacture comprises a sink.

(15) The method of Claim 13 wherein said article of manufacture .comprises a toilet bowl.

(16) The method of Claim 13 wherein said article of manufacture comprises a kitchen countertop.

(17) An apparatus for selectively forming an article of manufacture, said apparatus comprising a mold; a reservoir of a catalyst; a reservoir of a structural foam material; a pump which ^" is physically and communicatively coupled to said reservoir of structural foam material; a mixing head ^• assembly which is physically and communicatively coupled to said pump and which includes an auxiliary input port and an output port; a source of gas which is physically and communicatively coupled to said- auxiliary input port; a mixing assembly ^• which is physically and communicatively coupled to said output port of said mixing _.head assembly; and a controller which is controllably coupled to said pump, to said source of gas, and to said mixing assembly and wherein said controller is adapted to selectively cause at least a portion of said reservoir of structural foam material to be communicated to said input port of said mixing head assembly while causing at least a portion of said source of gas to be communicated to said auxiliary input port of said mixing head assembly , thereby causing at least said portion of said source of gas to -mix with said at least said portion of said reservoir of structural foam within said mixing head assembly to form a certain material, said controller further selectively causing said formed certain material to be communicated to said mixing assembly and causing said formed certain material to mix with at least a portion of said catalyst material within said mixing assembly to form a certain second material and further selectively causing at least a portion of said formed certain second material to be selectively dispensed from said mixing assembly to said mold, thereby allowing said certain second material to form said article of manufacture within said mold.

(18) The apparatus of Claim 17 further comprising a selectively ^'activatable vibration assembly which is controllably coupled to. said controller and which isphysically coupled to said mixing head assembly and wherein said controller selectively activating said vibration assembly when said gas and said structural foam are mixed within said mixing head assembly, thereby causing said gas and said structural foam to vibrate as they are being mixed within said mixing head assembly.

(19) The apparatus of .Claim 18 wherein said gas comprises air.

(20) The apparatus of Claim 19 further comprising a selectively activatable heating assembly which is controllably coupled - to said controller and which is coupled to said source of gas and wherein said controller selectively activates said heating assembly to cause said gas to be heated before it is communicated to said auxiliary input port of said mixing head assembly. ^'5

(21) The apparatus of Claim 20 wherein said structural foam material comprises Terrocore.

(22) The apparatus of Claim 21 wherein said article of manufacture comprises a toilet bowel. (.

23) The apparatus of Claim 21 wherein said article of 10 manufacture comprises a kitchen countertop.

(24) The apparatus of Claim 21 wherein said article of manufacture comprises a sink.

(25) An apparatus for selectively forming an article of manufacture, said apparatus comprising a mold; a reservoir

15 • , of a catalyst; a reservoir of a syntactic cement; a pump which is physically and communicatively coupled to said reservoir of syntactic cement; a mixing head assembly which is physically and communicatively coupled to said pump and which includes an auxiliary input port and an output port;

20_. a source of gas which is physically and communicatively coupled to said auxiliary input port; a mixing assembly which is physically and communicatively coupled to said output port of said mixing head assembly; and a controller which is controllably coupled to said pump, to said source of gas, and ^' to said mixing assembly and wherein said controller is adapted to selectively cause at ^' least a •portion of said reservoir of syntactic cement to be communicated to said input port of said mixing head assembly while causing at least a portion of said source of gas to be communicated to said auxiliary input port of said mixing head assembly, thereby ^'causing at least said portion of said source of gas to mix with said at least said portion of said reservoir of syntactic cement within said mixing head assembly to ^• form a certain material, said controller further selectively causing said formed certain material to be communicated to said mixing assembly and causing said formed certain material to mix with at least a portion of said catalyst material within said mixing assembly to form a certain second material and further selectively - causing at least- a portion of said formed certain second material to be selectively dispensed from said mixing assembly to said mold, thereby allowing said certain- second material to form said article of manufacture within said mold.

(26) The apparatus ^"of Claim 25 wherein said catalyst comprises water.

(27) The apparatus of Claim 26 further comprising a selectively activatable heating assembly which is controllably coupled to said . controller ^" and which is coupled to said source- of gas and wherein said controller selectively ^' activates said heating assembly to cause said gas to be heated before it is communicated to said auxiliary input port of said mixing head assembly.

(28) The apparatus of Claim 27 wherein said article of manufacture comprises a toilet bowel.

(29) The apparatus of Claim 27 wherein said article of. manufacture comprises a ' kitchen countertop.

(30)' The apparatus of Claim 27 wherein said article of manufacture comprises a sink.

(31) An article of manufacture made by the process of mixing a structural foam material with a catalyst material to form a selectively mixed material; placing the selectively mixed material into a mold; and allowing the selectively mixed material to harden within the mold, thereby forming said article of manufacture.

(32) The article of manufacture of Claim 31- comprising a toilet bowel. ^■

(33) The article of manufacture of Claim 31 comprising a sink.

(34) The article of manufacture of Claim 31 comprising a counter top.

(35) The article of manufacture of Claim 31 wherein said structural foam material comprises Terrocore.

(36) The article of manufacture of Claim 35 wherein said catalyst material comprises an amine catalyst.

(37) The article of manufacture of Claim 36 further comprising the steps of causing hot gas to be mixed with said structural foam material and said catalyst.

(38) The article of manufacture of Claim 37 further comprising the steps of causing said structural foam material and said catalyst to be vibrated as they are selectively mixed.

(39) The article of manufacture of Claim 38 further comprising the steps of finishing the surface of said hardened material .

(40) An article of manufacture made by the process of mixing a syntactic cement material with a catalyst material to form a selectively mixed material; placing the selectively mixed material into a mold; and allowing the selectively mixed material to harden within the mold, thereby forming said article of manufacture.

(41) The article of manufacture of Claim 40 comprising a toilet bowel.

(42) The article of manufacture of Claim 40 comprising a sink.

( 43 ) _. The article of manufacture of Claim 40 comprising a. counter top .

(44) The article of manufacture of Claim 40 wherein said syntactic cement material comprises cyanoacrylate.

(45) The article of manufacture of Claim 40 wherein said catalyst material comprises water.

(46) The article of manufacture of Claim 45 further comprising the steps of causing hot gas to be mixed with said syntactic cement material and said catalyst. (47) The article of manufacture of Claim 46 further comprising the steps of causing said syntactic cement material and said catalyst to be vibrated as they are selectively mixed. (48) The article of manufacture of Claim 47 further comprising the steps of finishing the surface of said hardened material. (49) The article of manufacture of Claim 48 further comprising the steps of providing microspheres; and placing said provided microspheres within said syntactic cement. (50) The article of manufacture of Claim 49 further comprising the step of selectively vibrating said mold.